AWS C6.2/C6.

2M:200X
An American National Standard

Specification for

Qualification of Friction Welding of Metals

DRAFT #DS-2 - March 30, 2001

American Welding Society

Draft DS-2 March 29, 2001 -1-

Key Words - Friction welding, direct AWS C6.2/C6.2M:200X
drive, inertia, welding An American National Standard
procedure specification,
equipment, quality-assurance
categories, safety

Approved by
American National Standards Institute
MMMMMMM DD, 200X

Specification for
Qualification of
Friction Welding of
Metals
Prepared by
AWS C6 Committee on Friction Welding

Under the Direction of

AWS Technical Activities Committee

Approved by
AWS Board of Directors

Abstract

This specification provides for the qualification of friction welding machines, procedures,
and training of welding operators. Qualification of the welding procedure specification (WPS)
includes the material specifications involved, weld joint design, destructive and nondestructive
testing requirements, as well as guidelines for different categories of quality assurance.
Qualification of welding equipment includes weld parameter control, weld reproducibility, and
basic safety requirements.

Welding operators require training in the proper operation of friction welding equipment
and general safety procedures. The requirements for requalification of the WPS and equipment
are also given.

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 American Welding Society
550 N.W. LeJeune Road, Miami, FL 33126

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 Statement on Use of AWS American National Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding
Society are voluntary consensus standards that have been developed in accordance with the rules of the American National
Standards Institute. When AWS standards are either incorporated in, or made part of, documents that are included in federal or
state laws and regulations, or the regulations of other governmental bodies, their provisions carry the full legal authority of the
statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory
jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authority
of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or
deviations from requirements of an AWS standard must be by agreement between the contracting parties.

International Standard Book Number: 0-87171-631-3

American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126

© 200X by American Welding Society. All rights reserved

Printed in the United States of America

AWS American National Standards are developed through a consensus standards development process that brings together
volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the process and
establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the
accuracy of any information or the soundness of any judgments contained in its standards.

AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special,
indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this standard.
AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein.

In issuing and making this standard available, AWS is not undertaking to render professional or other services for or on behalf of
any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity to someone else. Anyone using
these documents should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent
professional in determining the exercise of reasonable care in any given circumstances.

This Standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.
Publication of this standard does not authorize infringement of any patent. AWS disclaims liability for the infringement of any
patent resulting from the use or reliance on this standard.

Finally, AWS does not monitor, police or enforce compliance with this standard, nor does it have the power to do so.

Official interpretations of any of the technical requirements of this standard may be obtained by sending a request, in writing, to
the Managing Director Technical Services, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126 (See Annex
B). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered.
However, such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not
speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In
addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS C6 Committee on Friction Welding. It must be reviewed every 5
years and if not revised, it must be either reapproved or withdrawn. Comments (recommendations, additions, or deletions) and
any pertinent data that may be of use in improving this standard are requested and should be addressed to AWS Headquarters.
Such comments will receive careful consideration by the AWS C6 Committee on Friction Welding and the author of the
comments will be informed of the Committee's response to the comments. Guests are invited to attend all meetings of the AWS
C6 Committee on Friction Welding to express their comments verbally. Procedures for appeal of an adverse decision concerning
all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be
obtained from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.

Photocopy Rights

Authorization to photocopy items for internal, personal, or educational classroom use only, or the internal, personal, or
educational classroom use only of specific clients, is granted by the American Welding Society (AWS) provided that the
appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, Tel: 978-750-8400;
online: http://www.copyright.com.

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 Personnel

AWS C6 Committee on Friction Welding

T. Stotler, Chair Edison Welding Institute

M. Skinner, 1st Vice Chair MTS Systems Corporation
E. Mitchell, Secretary American Welding Society
C. W. Carrier General Electric Company
J. R. Huber A R D Industries Limited
C. A. Johnson NAWCPNS - China Lake
G. A. Knorovsky Sandia National Laboratories
D. L. Kuruzar Manufacturing Technology, Incorporated
T. J. Lienert Edison Welding Institute
J. Price Thompson Friction Welding
W. Seeds American Axle and Manufacturing
D. E. Spindler Manufacturing Technology, Incorporated
J. S. Thrower Extec Limited
A. S. Wadleigh Interface Welding
D. J. Walsh Walsh Friction Welding, Incorporated

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 Foreword

(This Foreword is not a part of AWS C6.2/C6.2M:200X, Specification for Qualification

of Friction Welding of Metals, but is included for information purposes only.)

This Specification for Qualification of Friction Welding is the second publication of the
AWS C6 Committee on Friction Welding. The committee was formed to recognize, codify,
develop, and advance the process of friction welding.

The Committee’s first publication, ANSI/AWS C6.1-89, Recommended Practices for

Friction Welding was completed and published in 1989. It was the culmination of a monumental
task: assembling and reducing into a concise form, the technology and history of friction
welding.

It was recognized at that time that a second document, a specification, would be required.
A task force from within the AWS C6 Committee was formed to prepare a specification for
approval.

The purpose of this specification is to help ensure that the welds resulting from using this
specification meet the service requirements for which they are intended.

This document clearly and accurately describes the essential technical requirements for a
friction weld. It specifies the qualification of procedures, methods, and equipment necessary to
meet its technical requirements and safe use. This specification is intended to be used when
referenced by other specifications or contract documents.

Comments and suggestions for the improvement of this standard are welcome. They
should be sent to the Secretary, Committee on Friction Welding, American Welding Society, 550
N.W. LeJeune Road, Miami, FL 33126.

Official interpretations of any of the technical requirements of this standard may be

obtained by sending a request, in writing, to the Managing Director, Technical Services,
American Welding Society. A formal reply will be issued after it has been reviewed by the
appropriate personnel following established procedures.

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 Table of Contents

Page No.

Personnel .......................................................................................................................
Foreword .......................................................................................................................
List of Tables ..................................................................................................................
List of Figures ................................................................................................................

1. Scope ........................................................................................................................

2. Reference Documents..................................................................................................

3. Process Description ....................................................................................................

4. General Requirements.................................................................................................
4.1 Equipment Requirements ................................................................................
4.2 Material Requirements....................................................................................
4.3 Weld Joint Design..........................................................................................

5. Welding Procedure Specification (WPS) Qualification ...................................................

5.1 WPS Qualification Requirement ......................................................................
5.2 Allowable Parts for WPS Qualification Purposes...............................................
5.3 Examination of Parts Welded to Qualify a WPS ................................................
5.4 Circumstances Mandating Requalification ........................................................
5.5 Machine-Specific Nature of a WPS ..................................................................
5.6 Requalification Procedure Requirements ..........................................................

6. Welding Operator Qualification ...................................................................................

6.1 Safety ...........................................................................................................
6.2 Operator Qualification Requirements ...............................................................
6.3 Operator Requalification Requirements ............................................................

7. Quality Assurance.......................................................................................................
7.1 Categories .....................................................................................................
7.2 WPS Qualification-Acceptance Criteria............................................................
7.3 Production Quality Assurance .........................................................................

8. Equipment Safety........................................................................................................
8.1 Responsibility................................................................................................
8.2 Inherent Hazard Protection..............................................................................
8.3 Power-Clamping Work-Holding Devices..........................................................
8.4 Anti-Motion Mechanisms or Counterbalance on Slide Mechanisms.....................
8.5 Tool Retention ...............................................................................................
8.6 Hazards Involved with FRW/FSW ...................................................................

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 Table of Contents
(Continued)
Page No.

9. Personnel Safety.........................................................................................................
9.1 Responsibility................................................................................................
9.2 Hazard Protection...........................................................................................
9.3 Safety Apparatus............................................................................................

10. Safe Use, Care, Installation, and Maintenance.............................................................

10.1 Provision of Maintenance and Operation Manual.............................................
10.2 Manufacturer's Responsibility........................................................................
10.3 Reconstructor's or Modifier's Responsibility....................................................
10.4 Employer Responsibility ...............................................................................
10.5 Installer's Responsibility ...............................................................................

11. Use..........................................................................................................................
11.1 Machine Manufacturer's Responsibility ..........................................................
11.2 Machine Modifier's or Reconstructor's Responsibility ......................................
11.3 Employer Responsibility ...............................................................................
11.4 Employee Responsibility...............................................................................

Annex A — Terms and Definitions.....................................................................................

Annex B — Guidelines for Preparation of Technical Inquiries for AWS Technical Committees

AWS List of Documents on Friction Welding ....................................................................

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 List of Tables
Table
Page No.

1 Production Quality-Assurance Categories ...............................................................

List of Figures
Figure
Page No.

1 Weld Procedure Specification (WPS) Example for Direct-Drive Friction Welding ......

2 Weld Procedure Specification (WPS) Example for Inertia Friction Welding ...............

3 Weld Procedure Specification (WPS) Example for Friction Stir Welding ...................

4 Weld Procedure Specification (WPS) Example for Production Sampling ...................

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 Specification for Qualification of Friction Welding

1. Scope

This document specifies the requirements for the manufacture and quality assurance of
friction weldments. It also contains requirements for the qualification of welding machines,
welding procedures, and welding operators and for quality assurance of production weldments.

This standard makes use of both the International System of Units (SI) and U.S.
Customary Units. The measurements may not be exact equivalents; therefore, each system must
be used independently of the other without combining in any way. The standard designation
C6.2:2000 uses U.S Customary units. The standard with the designation C6.2M:2000 uses SI
units. The latter are shown within brackets [ ] or in appropriate columns in tables and figures.

2. Reference Documents

This document is not a stand-alone document. Recommended practices may be found in

AWS C6.1, Recommended Practices for Friction Welding. Documents on inspection and testing
of welds are listed in this section. The following documents form a part of this specification.

AWS A2.4, Standard Symbols for Welding, Brazing, and Nondestructive Examination
AWS A3.0, Standard Welding Terms and Definitions
AWS B4.0, Standard Methods for Mechanical Testing of Welds
ANSI B15.1, Safety Standard for Mechanical Power-Transmission Apparatus1
ANSI Z535.1, Safety Color Code
ANSI Z535.2, Environmental and Facility Safety Signs
ANSI Z535.3, Criteria for Safety Symbols
ANSI Z535.4, Product Safety Signs and Labels
ANSI Z535.5, Accident Prevention Tags (for Temporary Hazards)

Other reference documents are:

AWS Safety and Health Fact Sheets

ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes (published by the American
Welding Society)
ANSI B11.6, American National Standard for Machine Tools-Lathes-Safety Requirements for
Construction, Care, and Use
MIL-STD-1252, Inertia Friction Welding, Process, Procedure, and Performance Qualification
(Note: This standard is considered obsolete by the AWS C6 Committee on Friction
Welding since direct-drive friction welding is not recognized. Also, the allowed ±10%
variation in faying surface area is unwarranted unless the welds tested qualify to a
procedure reflecting this variation.)

3. Process Description
1
Available from American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036.
1

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 Friction welding (FRW) is a solid-state joining process that produces coalescence of
materials under compressive force contact of workpieces rotating or moving relative to one
another to produce heat and plastically displace material from the faying surfaces. Filler metal,
flux, and shielding gas are not normally required with this process.

Friction stir welding (FSW) is a variation of FRW that produces a weld between two
butted workpieces by the friction heating and plastic material displacement caused by a high-
speed rotating tool that traverses along the weld joint.

4. General Requirements

Users of friction welding and friction stir machines are expected to inform themselves of
and comply with applicable national and local requirements regulating industrial practices.

4.1 Equipment Requirements

4.1.1 A machine capable of controlling the friction speed, applied forces, and/or
displacement rates/distances such that it can produce welds made to a qualified welding
procedure specification (WPS) within the tolerances established is considered qualified.

4.1.2 Systems, which control machine-operating variables, shall be calibrated. The

maximum interval between calibrations shall be twelve (12) months. The calibration accuracy
and precision shall be to a level required to produce parts within tolerances established by the
WPS.

4.1.3 The machine shall be equipped with an automatic control system which
sequentially completes the welding cycle without welding operator intervention after initiation.

4.1.4 The machine shall be set-up and verified to be in conformance with the WPS by
the appropriate trained personnel as determined by the Engineer.

4.2 Material Requirements. Material properties necessary to fulfill the engineering

drawing requirements should be specified. Typical properties that may be specified are the
following:

(1) Chemical composition

(2) Incoming material heat treatment
(3) Metallurgical cleanliness
(4) Discontinuities
Other material requirements may be controlled by supplementary specifications.

4.3 Weld Joint Design. The joint should be specified by a welding symbol (see AWS 2.4 on an
assembly drawing. Features which should be specified on process drawings prior to welding,
include:

(1) Dimensions (including tolerances)

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 (2) Faying surface finish
(3) Faying surface cleanliness
(4) Heat treatment

5. Welding Procedure Specification (WPS) Qualification

5.1 WPS Qualification Requirement. A WPS should be qualified prior to production welding.
Examples of WPS forms appear as Figures 1, 2, and 3. An example of a Quality Control form is
shown in Figure 4. The WPS must include a Quality Control form.

5.2 Allowable Parts for WPS Qualification Purposes. Parts used for WPS qualification
purposes must be representative of those used for actual production parts in the following
respects:

(1) Chemical composition

(2) Faying surface condition
(3) Heat treatment
(4) Joint geometry and rotational mass
(5) Part dimensions

It is recommended that actual production parts will be used whenever feasible.

5.3 Examination of Parts Welded to Qualify a WPS. For welds requiring postweld heat
treatment (PWHT), the examination shall take place after PWHT.

5.3.1 Parts being evaluated to qualify a proposed WPS must undergo examination/testing
as specified on the appropriate engineering drawing. Acceptance criteria shall be included with
the testing requirements.

5.3.2 If not specified on the drawing, minimum examination/testing and acceptance

requirements are:

5.3.2.1 A minimum of two (2) parts shall be welded for WPS qualification and

5.3.2.2 A minimum of two (2) parts shall be examined. The examination shall include
both a destructive mechanical test and a metallographic examination. The metallographic
specimen shall be examined both macroscopically (10-30×) and microscopically (100×).

5.3.2.3 Acceptance or rejection shall be according to standards established in Section 7.

Quality Assurance.

5.4 Circumstances Mandating Requalification. A WPS shall remain qualified unless the
following occurs:

(1) Modifications or repairs are made to the machine which affect its welding
performance.

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 (2) Component dimensions exceed tolerances established in the WPS.
(3) Materials or material conditions, or both, change from those specified in the WPS.
(4) Preparation of faying surfaces changes from that specified on the WPS.
(5) Unexplained nonconformity with WPS-mandated quality-assurance requirements
occurs.

5.5 Machine-Specific Nature of a WPS. A WPS is developed for a specific welding machine;
it shall not be used on another machine without requalification, except by agreement between the
supplier and customer.

5.6 Requalification Procedure Requirements. Requalification procedure requirements are

identical to the qualification procedure requirements.

6. Welding Operator Qualification

FRW/FSW is an automatic, machine-controlled welding operation, thus operators do not require

welder certification. Instead, such personnel must meet the requirements of this section.

6.1 Safety. Operators/set-up personnel shall be trained in safe operating practices and hazard-
communication practices in accordance with national and local safety regulations.

6.2 Operator Qualification Requirements. Appropriate instruction shall be given in the

operation of a specific welding machine by an engineer or welding supervisor or a previously
qualified operator. Such instruction shall include all items covered by a WPS for which the
operator is responsible. In those cases where the operator does not have responsibility for
machine set-up, he need not be so instructed.

After such instruction, the welding operator shall demonstrate the ability to operate the
machine and to produce acceptable welds. Acceptance criteria for the qualification test weld
shall be determined by the Engineer. Welding operators shall be qualified for each (welding
machine to be or) WPS used in production. Operator qualification shall be documented.

6.3 Operator Requalification Requirements. Requirements for requalification of operators

are at the discretion of the Engineer.

7. Quality Assurance

In order to manufacture quality friction weldments, certain conditions must be met. The
following paragraphs define these requirements.

This section specifies three quality-assurance categories that may be applied regardless of
industry or product line (see Table 1). The designer, product, manufacturing, or process engineer
shall specify a quality-assurance category that is best suited to the welded component or
assembly. Exceptions to the requirements of this section must be specified in contract
documents or on the engineering drawings.

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 Friction welds and friction stir welds are utilized in very different applications in many
different situations. Friction welds or friction stir welds in industrial applications cannot be
divided generally into groups and cannot be determined to be more critical, less critical, or not
critical in service. Every friction weldment is critical, but each application’s demands and each
weldment’s “fitness for service” requires particular and individual quality-assurance programs.

7.1 Categories.
7.1.1 Category A. Every weld is checked visually and by a nondestructive testing
(NDE) method listed in the latest edition of AWS B1.10, Guide for Nondestructive Examination
of Welds. If applicable, a bend test or other destructive test as specified by the engineer shall be
performed in accordance with the latest edition of AWS B4.0, Standard Methods for Mechanical
Testing of Welds. Specified process monitoring parameters and physical dimensions for each
weldment shall be recorded. These records shall be maintained for an agreed upon period of
time.

7.1.2 Category B. An agreed upon weld sample shall be checked visually and by an
NDE method listed in the latest edition of AWS B1.10, Guide for Nondestructive Examination of
Welds. Alternatively, if no welds are checked by NDE, then a bend test or other destructive test
as specified by the Engineer shall be performed on a specified sample number of weldments.
Bend testing, if used, shall be in accordance with AWS B4.0. Specified process monitoring
parameters for all weldments will be within acceptable limits, but not necessarily recorded.
Physical dimensions for an agreed upon sample of the weldments will be recorded and
maintained for an agreed upon period of time.

7.1.3 Category C. Sample weldments shall be visually and destructively examined, and
shall have specified process monitoring parameters and dimensions checked. There are no
record-keeping requirements. As a minimum, the beginning or end of a shift or batch is the most
appropriate time to perform these actions.

7.2 WPS Qualification-Acceptance Criteria. WPS qualification acceptance criteria are the
following:

7.2.1 Metallographic Evaluation Criteria. The weld heat-affected zone (HAZ) shall
be free of discontinuities such as cracks, inclusions, and porosity. Acceptability of brittle phases
must be evaluated on the basis of their effect on appropriate mechanical properties. Acceptance
standards of the base metal specifications shall be used to determine the acceptability of features
resulting from inclusions and stringers in the base metal.

7.2.2 Mechanical Test Criteria. The mechanical test of the weld specimen shall pass
the criteria specified on the engineering drawing. If no mechanical testing procedure is specified
on the drawing, a bend test shall be performed in accordance with AWS B4.0, Standard Methods
for Mechanical Testing of Welds. Test specimens defined in Parts A and D may be used
depending upon the size of weldment being tested. If specimens defined by Part A are used, they
shall include the center and edge of the weld where appropriate (i.e., solid bar welds) or at the
beginning, middle, and end of a FSW. Criteria for passing the bend test shall be agreed upon
between the weldment supplier and customer.

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7.3 Production Quality Assurance. To maintain acceptable production quality assurance the
following shall apply:

7.3.1 Welds shall be made by a qualified machine operator according to the requirements
of the WPS.

7.3.2 When machines are equipped with monitors, they shall be set and used in
accordance with the WPS.

7.3.3 Sampling of production welds shall be used for quality assurance in accordance
with the WPS. In the absence of other contractual quality-assurance requirements, one (1) bend
test shall be made and evaluated according to the criteria given in 6.2 at the beginning of each
production run.

7.3.4 Statistical process control may be applied to measure physical dimensions of the
weldment, upset length, or other process variables.

7.3.5 Documentation shall be maintained for an agreed upon period of time.

8. Equipment Safety

8.1 Responsibility
8.1.1 Manufacturer. It shall be the responsibility of the welding machine
manufacturers to design and construct their equipment in compliance with national and local
safety standards as well as the applicable portions of this specification.

8.1.2 Reconstructor or Modifier. It shall be the responsibility of any person

reconstructing or modifying a FRW or FSW machine to do so in compliance with national and
local safety standards as well as the applicable portions of this specification.

8.2 Inherent Hazard Protection

8.2.1 Power Transmission Components. The manufacturer shall eliminate any hazard
associated with power transmission components by design or shall provide protection against the
hazard in accordance with ANSI B15.1, Safety Standard for Mechanical Power Transmission
Apparatus. Where the hazard cannot be eliminated by design or protection, the manufacturer
shall warn against the hazard by safety color coding or affixing a permanent warning sign in
accordance with ANSI Z535.1, Safety Color Code, ANSI Z535.2, Environmental and Facility
Safety Signs; ANSI Z535.3, Criteria for Safety Symbols, ANSI Z535.4, Product Safety Signs and
Labels, and ANSI Z535.5, Accident Prevention Tags (for Temporary Hazards).

8.2.2 Pinch Points Due to Welding Machine Movement. The manufacturer shall
eliminate the pinch points created by moving parts of the welding machine or shall provide
protection against the hazard.

8.3 Power-Clamping Work-Holding Devices

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 8.3.1 Friction Welder - Lack of Pressure in Clamp Side of Actuator when Starting
Rotation. Where a lack of pressure on the clamp side of the actuator can result in a foreseeable
risk of injury, power-clamping devices shall be provided with an interlock safeguard to prevent
injury to the operator. The interlock shall prevent rotation of the workpiece until adequate
pressure is detected in the clamp side of the actuator. Exception: jogging the spindle in a
manual mode may be permitted.

8.3.2 Power Loss to Work-Holding Devices. When power is required to maintain

clamping force and where failure of such power presents a hazard to personnel due to accidental
release of the workpiece, a method shall be provided to either safely contain the workpiece or to
safely stop the machine while maintaining sufficient clamping force to hold the workpiece.

8.3.3 Unclamping a Workpiece. Where unclamping the workpiece will result in a

hazard to personnel, a method shall be provided to prevent unclamping while the workpiece is
being power driven.

The unclamp control shall be protected from unintentional operation.

8.4 Anti-Motion Mechanisms or Counterbalance on Slide Mechanisms. All new or

reconstructed welding machines should be provided with an anti-motion mechanism or
counterbalance system to prevent or retard unintended movement of the slide mechanism.

8.5 Tool Retention. Cutting tool systems should retain the cutting tool during the machining
cycle. These mechanisms should not release as a result of power loss.

8.6 Hazards Involved with FRW/FSW

8.6.1 Hot Parts. Welded parts are heated locally to temperatures near the melting point.
Subsequent heat redistribution (particularly in aluminum and copper alloys) can cause general
heating of the part and fixtures to the point where, as with any welded parts, appropriate handling
precautions shall be taken.

8.6.2 Hazardous Vapors, Dusts, and Fumes. FRW/FSW generates high temperatures
which may cause the formation of metal vapors, fumes, and dusts. Consideration shall be given
to ventilation requirements.

8.6.3 Flash Removal. The chips resulting from friction weld flash removal are
extremely hot and shall be handled with caution. It is not safe to handle the chips immediately
after they are produced with gloves alone.

9. Personnel Safety

9.1 Responsibility. It shall be the responsibility of the employer to provide and ensure the
usage of safety apparatus, required by the subsequent portions of this section, as long as the
apparatus themselves do not create a hazard.

9.2 Hazard Protection

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 9.2.1 Point-of-Operation Hazard. The point of operation on welding machines shall
require safeguarding.

9.2.2 Loading and Unloading Power-Operated Work-Holding Devices. When

power-operated work-holding devices have clearance 0.24 in. [6 mm] or more from the surface
of the workpiece to be gripped, a means shall be provided to protect the operator.

9.2.3 Tool-Trapping Space. Tool-trapping space is space in which motion other than
welding takes place, such as, but not limited to, slide advance, head stock advance, jaws
clamping, shear tool motion, or tool slide motion if flash turning is employed. A safety
apparatus shall be required for welding machines when operating in semiautomatic or automatic
cycles and any motion not directly controlled by the operator. There are two exceptions:

(1) The operator is effectively protected by his or her position relative to the tool-
trapping space, and assured by such as space restraints on the operator or a continued
presence switch (light curtains or pressure-sensitive mats).
(2) The welding machine operates in a manual or set-up mode, and each motion is
controlled step by step by the operator.

9.2.4 Chips and Flash. A permanent safeguarding means shall be provided when
necessary to prevent chips and flash from being thrown on the operator, the operator’s work area,
or other assigned work area or aisle. Chips shall be removed by the use of a tool, puller, brush,
or shovel.

9.3 Safety Apparatus

9.3.1 Fixed Guards. Fixed guards used to satisfy the requirements of this standard shall
do the following:

(1) Prevent entry of parts of the body into the hazardous areas being guarded.
(2) Create no pinch points between themselves and moving parts of the welding machine
or tooling.
(3) Be securely attached to the welding machine frame, component, or fixture, and
utilize fasteners not readily removable by the operator.

9.3.2 Movable (Interlocked) Guards. Movable guards used to satisfy the requirements
of this standard shall do the following:

(1) Be in position manually or automatically before actuation of the machine cycle and
be interlocked so the welding machine will not operate until this guard is in position.
(2) Prevent entry of parts of the body into the hazardous areas being guarded.
(3) Create no pinch points between themselves and other stationary or moving parts of
the welding machine or tooling.
(4) Contain an interlock so arranged that it cannot be accidentally actuated.

9.3.3 Other Interlocks. Interlocks used to satisfy the requirements of this standard shall
protect the operator by one or more of the following:

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 (1) Requiring the concurrent application of both the operator’s hands to the machine
controls until the hazard being protected against is no longer present.
(2) Establishing the operator’s position so that the body is excluded from the hazardous
area.
(3) Stopping the machine cycle by use of a presence-sensing device which actuates if the
operator’s hand or other part of the body enters the area that this device is designed to
protect.

9.3.3.1 Presence-Sensing Guarding Device. A presence-sensing guarding

device, when used, shall be interlocked into the control circuit to prevent or stop machine motion
if an operator’s hand or other part of the body is detected in the sensing field of the device. The
device shall meet the following requirements:

(1) It shall not create any hazard to the operator.

(2) It shall not be used as a cycle-start mechanism.
(3) It shall be designed to fail safe so that failure of the device power source, excessive
ambient light, temperature variations, or other environmental factors shall not adversely
affect the protection offered to the operator.

9.3.3.2 Two-Hand Control. A two-hand control shall meet the following

requirements:

(1) It shall have the individual operator’s hand controls protected against unintentional
operation.
(2) It shall have the individual operator’s hand controls arranged by design and
construction, or separation, or both, to require the use of both hands to initiate the
welding cycle.
(3) It shall use a control arrangement requiring concurrent operation of the individual
operator’s hand controls.

10. Safe Use, Care, Installation, and Maintenance

10.1 Provision of Maintenance and Operation Manual. The manufacturer or modifier shall
provide a maintenance and operation manual for all welding machines built new, modified, or
reconstructed.

10.2 Manufacturer's Responsibility. It shall be the responsibility of the manufacturer to

provide instructions for the safe use, care, installation, and maintenance of the welding machine.
For a product with unique characteristics, specific instructions shall be provided.

10.3 Reconstructor's or Modifier's Responsibility. It shall be the responsibility of any

person(s) reconstructing or modifying a machine to provide instructions for the safe use, care,
installation, and maintenance of the machine as modified.

Draft DS-2 March 29, 2001 -18-

10.4 Employer Responsibility. It shall be the responsibility of the employer to maintain the
welding machine in safe operating condition. Maintenance personnel shall follow safe practices
in maintaining the welding machine.

10.4.1 Maintenance Manual Availability. The employer shall utilize any pertinent
information contained in the maintenance manual provided as a part of the information made
available to maintenance personnel for new welding machines and for those modified or
reconstructed.

10.4.2 Maintenance Personnel. The employer shall ensure that maintenance personnel
follow the instructions, procedures, and training set forth by the employer to meet the
requirements of this standard.

10.5 Installer's Responsibility. It shall be the responsibility of the person(s) installing a

welding machine to use procedures that will allow for a safe installation.

11. Use

11.1 Machine Manufacturer Responsibility. For each new welding machine, the machine
manufacturer shall provide an operations manual.

11.2 Machine Modifier's or Reconstructor's Responsibility. The modifier or reconstructor of

the machine shall provide an operations manual for the machine as modified or reconstructed.

11.3 Employer Responsibility

11.3.1 Instruction of Employees. The employer shall ensure that training and
instruction for set-up personnel, operator, and helpers in the safe method of performing any
operation on the type of welding machine used occurs before the employee(s) will be able to
operate or set-up.

11.3.2 Safety Instructions. Special emphasis shall be placed on instructing

inexperienced employees concerning hazards involved in the following areas of welding
machine operation.

11.3.3 Supervision. The employer shall ensure by supervision that safe operating
procedures are being followed.

11.3.4 Operations Manual (Employer). For all welding machines, the employer shall
make the operations manual available to individuals setting up or operating the welding
machines.

11.3.5 Personal Protective Equipment. The employer shall determine what personal
protective equipment is needed when operating friction welding or friction stir machines and
shall enforce the proper use of this equipment.

Draft DS-2 March 29, 2001 -19-

 11.3.6 Work Area. Provision shall be made for the safe storage and handling of tooling
and parts that could dislodge and fall, or roll. The floor area of the operator’s work position shall
be cleaned to prevent oil, grease, and chips from accumulating in order to prevent a hazardous
condition.

11.3.7 Overloading. The employer shall require that all welding machines and auxiliary
equipment be operated within their safe capacity ratings and specified by the manufacture,
modifiers, or reconstructors.

11.3.8 Guards, Devices, Awareness Barriers, Awareness Devices, and Shields. It

shall be the responsibility of the employer to ensure that all guards, devices, awareness barriers,
awareness devices, and shields are in good condition and in place during operation of the
welding machine.

11.3.9 Set-Up. The employer shall ensure that only trained personnel are permitted to
perform welding machine set-ups.

11.3.10 Work-Driving and Holding Equipment. It shall be the responsibility of the

employer to provide, maintain, and enforce the use of work-driving and holding equipment that
is of adequate size, capacity, and condition to perform the type of operation required on the
welding machine. The gripping member (jaws) are subject to wear and damage during use and,
as such, can become ineffective in holding the workpiece. Periodic inspection and maintenance
shall be performed to ensure that proper gripping ability is maintained.

11.4 Employee Responsibility. The employee shall follow the instructions and directions set
forth by the employer to meet the requirements of this specification. Examples of the welding
machine operator’s, set-up operator’s, helper’s, or set-up person’s responsibilities include the
following:

(1) Follow all safety practices and procedures given in this specification that apply to their
actions and conduct.
(2) Notify the supervisor when an unsafe practice or condition is observed.
(3) Properly use all personal protective equipment as specified by the employer.
(4) Install, position, or adjust safety devices as instructed by the employer under the
provisions of this standard.
(5) Do not alter, remove, or disable any safety equipment without the approval of the
employer.
(6) Make a visual safety check of the set-up during each shift. Severe operating conditions
shall require more frequent checking.
(7) Do not wear clothing or jewelry that will present a hazard to their personal safety.
(8) Maintain an orderly work area. Particular attention shall be given to the storage of tools
or parts that could be dislodged and fall, or roll.

Draft DS-2 March 29, 2001 -20-

 Annex A
Terms and Definitions

(Nonmandatory Information)

(This Annex is not a part of AWS C6.2/C6.2M:200X, Specification for Qualification of

Friction Welding of Metals, but is included for information purposes only.)

The following includes friction welding terms not listed in AWS A3.0, Standard terms
and Definitions. Standard terms, found in A3.0, are listed in italics.

angular reciprocating friction welding. A variation of the friction welding process in which
the relative motion between the faying surfaces describes an arc of less than 180 degrees
and reverses direction repeatedly during the friction phase.

braking delay. The period of time between the cessation of the drive producing relative motion
of the workpieces, and the start of external braking.

braking phase. That portion of the welding cycle during which the external brake is applied.

braking rate. The reduction in speed vs. time during the braking phase.

braking time. The duration of the braking phase.

continuous-drive friction welding. See “direct-drive friction welding.”

cooling dwell. The time from the cessation of relative motion until the forge force is released,
during which time the weld cools.

direct-drive friction welding. A variation of friction welding in which the energy required to
make the weld is supplied to the welding machine through a direct motor connection for a
preset period of the welding cycle.

external braking. Forced reduction in the speed of relative motion by a built-in braking unit,
either internal to the motor or a separate mechanical brake.

faying surface. The mating surface of a member that is in contact with, or in close proximity to,
another member to which it is to be joined.

first friction force. The compressive force applied to the faying surfaces during the first friction
phase.

first friction phase. An optional application of a reduced friction welding force at the beginning
of the welding cycle.

Draft DS-2 March 29, 2001 -21-

first friction time. The duration of the first friction phase.

flash curl. See “weld flash.”

flash roll. See “weld flash.”

fly wheel energy. The total kinetic energy stored in the rotating mass of an inertia friction
welding machine when the friction welding force is applied.

flywheel friction welding. A variation of friction welding in which the energy required to make
the weld is supplied by the rotational kinetic energy of the welding machine. Also,
nonstandard term for Inertia Friction Welding.

forge delay time. The time between the cessation of drive and the initiation of the forge force.

forge force. A compressive force applied to the faying surfaces after the friction phase of the
welding cycle is essentially complete.

forge length. The change in component length which occurs during the forge phase.

forge phase. The portion of the friction welding cycle during which the forge force is applied to
the faying surfaces.

forge time. The duration of the forge phase.

friction force. Nonstandard term. See “Friction Welding Force.”

friction phase. The portion of the friction welding cycle during which the heat necessary for
welding is generated by relative motion and the application of a friction force at the
faying surface. Friction Phase is comprised of both first friction (if used) and second
friction.

friction speed. The relative velocity of the workpieces at the time of initial contact.

friction stir welding (FSW). A variation of friction welding that produces a weld between two
butting workpieces by the friction heating and plastic material displacement caused by a
high-speed rotating tool that traverses along the weld joint.

friction surfacing. Surfacing or cladding in which the principle of friction welding is used to
deposit material.

friction time. The duration of the friction phase.

friction upset distance. The decrease in length of the workpieces during the time of friction
welding force application.

Draft DS-2 March 29, 2001 -22-

friction welding. (FRW) A solid-state welding process that produces coalescence of materials
under compressive force contact of workpieces rotating or moving relative to one another
to produce heat and plastically displaced material from the faying surfaces.

friction welding force. The compressive force applied to the faying surfaces during the friction
phase.

heat-affected zone. (HAZ) The portion of the base metal whose mechanical properties or
microstructure have been altered by the heat of welding, brazing, or thermal cutting.

hybrid friction welding. A variation of friction welding in which the energy required for
welding is supplied by more than one source.

inertia friction welding. A variation of friction welding in which the energy required to make
the weld is supplied by the stored rotational kinetic energy of the welding machine.

linear reciprocating friction welding. A variation of the friction welding process in which the
relative motion between the faying surfaces is linear and reverses direction repeatedly
during the friction phase.

orbital friction welding. A variation of the friction welding process which produces an
elliptical motion between the faying surfaces.

prebond. The distance between the faying surfaces immediately prior to the application of the
friction welding force.

radial friction welding. A variation of the friction welding process which can be used to join
circular sections where it is undesirable to rotate the parts to be joined, or to join collars
and bands to the inside or outside of cylindrical sections. In this variation the applied
friction welding and forge forces between the faying surfaces are normal to the axis of
rotation.

second friction force. The compressive force applied to the faying surfaces during the second
friction phase.

second friction phase. The portion of the friction welding during which in conjunction with the
first friction phase comprises the friction phase. In the absence of the optional first
friction phase, this becomes the entire friction phase.

second friction time. The duration of the second friction phase.

surface velocity. The angular velocity measured at the outer periphery of the faying surfaces.

spin welding. Nonstandard term. See “friction welding.”

Draft DS-2 March 29, 2001 -23-

unit energy. The stored flywheel energy of an inertia friction welder divided by the area of the
faying surfaces.

unit force. The compressive force applied to the faying surfaces divided by the area of the
faying surfaces.

upset. Bulk deformation resulting from the application of pressure in welding. The upset may
be measured as a percent increase in interface area, a reduction in length, a percent
reduction in lap joint thickness, or a reduction in cross wire weld stack height.

upset distance. The total loss of axial length of the workpieces from the initial contact to the
completion of the weld. In flash welding, the upset distance is equal to the platen
movement form the end of flash time to the end of upset.

upset force. The force exerted at the faying surfaces during upsetting.

upset speed. The RPM at which the axial force is increased (typically used with inertia-friction
welding), if necessary, to the forge force. See also “forge phase.”

upset time. The time during upsetting.

weld flash. The material which is displaced from the friction weld interface.

weld interface. The interface between weld metal and base metal in a fusion weld, between base
metals in a solid-state weld without filler metal, or between filler metal and base metal in
a solid-state weld with filler metal and in a braze.

weld speed. The RPM at which the weld force is applied in inertia friction welding.

Draft DS-2 March 29, 2001 -24-

 Annex B
Guidelines for Preparation of Technical Inquiries for AWS Technical Committees

(Nonmandatory Information)

(This Annex is not a part of AWS C6.2/C6.2M:200X, Specification for Qualification of

Friction Welding of Metals, but is included for information purposes only.)

B1. Introduction

The AWS Board of Directors has adopted a policy whereby all official interpretations of
AWS standards will be handled in a formal manner. Under that policy, all interpretations are
made by the committee that is responsible for the standard. Official communication concerning
an interpretation is through the AWS staff member who works with that committee. The policy
requires that all requests for an interpretation be submitted in writing. Such requests will be
handled as expeditiously as possible but due to the complexity of the work and the procedures
that must be followed, some interpretations may require considerable time.

B2. Procedure

All inquiries must be directed to:

Managing Director, Technical Services

American Welding Society
550 N. W. LeJeune Road
Miami, FL 33126

All inquiries must contain the name, address, and affiliation of the inquirer, and they
must provide enough information for the committee to fully understand the point of concern in
the inquiry. Where that point is not clearly defined, the inquiry will be returned for clarification.
For efficient handling, all inquiries should be typewritten and should also be in the format used
here.

B2.1 Scope. Each inquiry must address one single provision of the Standard, unless the point of
the inquiry involves two or more interrelated provisions. That provision must be identified in the
Scope of the inquiry, along with the edition of the standard that contains the provisions or that
the Inquirer is addressing.

B2.2 Purpose of the Inquiry. The purpose of the inquiry must be stated in this portion of the
inquiry. The purpose can be either to obtain an interpretation of a Standard requirement, or to
request the revision of a particular provision in the Standard.

B2.3 Content of the Inquiry. The inquiry should be concise, yet complete, to enable the
committee to quickly and fully understand the point of the inquiry. Sketches should be used
when appropriate and all paragraphs, figures, and tables (or the Annex), which bear on the

Draft DS-2 March 29, 2001 -25-

inquiry must be cited. If the point of the inquiry is to obtain a revision of the Standard, the
inquiry must provide technical justification for that revision.

B2.4 Proposed Reply. The inquirer should, as a proposed reply, state an interpretation of the
provision that is the point of the inquiry, or the wording for a proposed revision, if that is what
inquirer seeks.

B3. Interpretation of Provisions of the Standard

Interpretations of provisions of the Standard are made by the relevant AWS Technical
Committee. The secretary of the committee refers all inquiries to the chairman of the particular
subcommittee that has jurisdiction over the portion of the Standard addressed by the inquiry.
The subcommittee reviews the inquiry and the proposed reply to determine what the response to
the inquiry should be. Following the subcommittee’s development of the response, the inquiry
and the response are presented to the entire committee for review and approval. Upon approval
by the committee, the interpretation will be an official interpretation of the Society, and the
secretary will transmit the response to the inquirer and to the Welding Journal for publication.

B4. Publication of Interpretations

All official interpretations will appear in the Welding Journal.

B5. Telephone Inquiries

Telephone inquiries to AWS Headquarters concerning AWS Standards should be limited

to questions of a general nature or to matters directly related to the use of the Standard. The
Board of Directors’ Policy requires that all AWS Staff members respond to a telephone request
for an official interpretation of any AWS Standard with the information that such an
interpretation can be obtained only through a written request. The Headquarters Staff can not
provide consulting services. The staff can, however, refer a caller to any of those consultants
whose names are on file at AWS Headquarters.

B6. The AWS Technical Committee

The activities of AWS Technical Committees in regard to interpretations, are limited

strictly to the Interpretation of provisions of Standards prepared by the Committee or to
consideration of revisions to existing provisions on the basis of new data or technology. Neither
the committee nor the Staff is in a position to offer interpretive or consulting services on: (1)
specific engineering problems; or (2) requirements of Standards applied to fabrications outside
the scope of the document or points not specifically covered by the Standard. In such cases, the
inquirer should seek assistance from a competent engineer experienced in the particular field of
interest.

Draft DS-2 March 29, 2001 -26-

 Table 1 - Production Quality-Assurance Categories

Quality
Assurance Visual Dimensional Dimensional Process Process NDE Destructive
Category Inspection Inspection Records Monitoring Records Testing Testing
A1 100% 100% 100% 100% 100% 100% Sample
A2 100% 100% 100% 100% 100% 100% None
B1 Sample Sample Sample 100% 100% Sample None
B2 Sample Sample Sample 100% 100% None Sample
C Sample Sample None Sample None None Sample

-27-
C6 Committee Ballot, Draft #DS-1, May 2000
 AWS C6.2/C6.2M:200X

Welding Procedure Specification

Direct-Drive Friction Welding

Date: Requalify on: Customer:

Welding Procedure Approved by: Part/Name/Number:
Welding Machine
Make: Location:
Model No.: Effective Weld Cylinder Area (in.2 or [mm2]):
Serial No.
Part Dimensions at Weld Area
Rotating Part Stationary Part
Joining Design (bar-to-bar, tube-to-tube, etc.)
Overall Initial Part Length (in. [mm]) (if tube)
Outside Diameter at Weld (in. [mm])
Inside Diameter at Weld (in. [mm]) (if tube)
Plate Thickness [in. or mm] if Applicable
Material Type/Specification
Bonding Surface Hardness (list units)
Part Stick Out from Tooling (in. [mm])
Machine Parameters
Primary Control Distance 1 or Time 1
Spindle Force Time Displacement
(RPM) (lbs or psig (sec) (in. or [mm])
[MPa]
Required
Spindle Clamp Pressure
Fixture Clamp Pressure
Preheat (1st Friction)
Heat (2nd Friction)
Forge Delay
Upset (Forge)
Upset (Forge) Hold Time
Optional
Brake Force
Brake Delay Prior to Upset
Minimum Time to Reach Upset Force
Preweld Butt Length
• Minimum
• Maximum
Total Cycle Time
• Minimum
• Maximum
Total Loss of Length
• Minimum
• Maximum
Finished Length
• Minimum
• Maximum
Flash Trim
Post-Weld Heat Treat (Yes/No). If yes, attach procedure specification.

Figure 1 - Weld Procedure Specification (WPS) Example for Direct-Drive Friction

WeldingProcedure Specification
 AWS C6.2/C6.2M:200X

Inertia-Friction Welding

Date: Requalify on: Customer:

Welding Procedure Approved by: Part/Name/Number:
Welding Machine
Make: Location:
Model No.: Effective Weld Cylinder Area (in.2 or mm2):
Serial No.
Part Dimensions at Weld Area
Rotating Part Stationary Part
Joining Design (bar-to-bar, tube-to-tube, etc.)
Overall Initial Part Length (in. or [mm]) (if tube)
Outside Diameter at Weld (in. or [mm])
Inside Diameter at Weld (in. or [mm]) (if tube)
Plate Thickness (in. or [mm]) if Applicable
Material Type/Specification
Bonding Surface Hardness (list units)
Part Stick Out from Tooling (in. or [mm])

Machine Parameters

Required
Spindle Clamp Pressure (psig [MPa])
Fixture Clamp Pressure (psig [MPa])
Spindle (RPM)
Total Inertia [Spindle, Tooling, and Flywheel Mass (wk2)]
Weld Force (lbs or psig [MPa])
Dwell Time (sec)
Optional
Upset Speed (RPM)
Upset Force (lbs or psig [MPa])
Total Cycle Time (sec)
• Minimum
• Maximum
Preweld Butt Length (in. [mm])
• Minimum
• Maximum
Total Loss of Length (in. [mm])
• Minimum
• Maximum
Flash Trim [Spindle RPM and/or Force (psig/lb [MPa])]
Post-Weld Heat Treatment (Yes/No). If yes, attach procedure specification.

Figure 2 - Weld Procedure Specification (WPS) Example for Inertia Friction Welding
 AWS C6.2/C6.2M:200X

Welding Procedure Specification

Friction Stir Welding

Date: Requalify on: Customer:

Welding Procedure Approved by: Part/Name/Number:
Welding Machine
Make: Location:
Model No.: Tool Design Reference No. (attach tool drawing):
Serial No.
Part Dimensions at Weld Area
Joining Design (butt, T, lap, etc.)
Overall Part Length (in. [mm])

Material Type/Specification
Machine Parameters
Primary Control Position 1 or Force 1
Rate
Spindle (in. /min) or Time Distance
(RPM) [m/min] (sec) (in. [mm])
Required
Plunge
Dwell after Plunge
Travel Speed
Dwell at End of Travel

Figure 3 - Weld Procedure Specification (WPS) Example for Friction Stir Welding
 AWS C6.2/C6.2M:200X

Welding Procedure Specification Quality Control

Production Sampling
Frequency Yes/No Time (specify units) Every “X” Pieces
At machine Startup
If Machine Idle for
Test After “X” Pieces or “X” Time
Test Sample to be Retained
• For How Long?

Test Data Requirements

Acceptance Criteria
Test Type Yes/No (use space below, if needed)
Metallographic
Bend Test
Tension
Other Mechanical (Define)
NDE

Test Data - Further Information

Joint Design Schematic

Figure 4 - Weld Procedure Specification (WPS) Example for Production Sampling

 AWS C6.2/C6.2M:200X

AWS List of Documents on Friction Welding

The following is a list of documents prepared by the AWS C6 Committee on Friction Welding:

AWS C6.1, Recommended Practices for Friction Welding

AWS C6.2/C6.2M, Specification for Qualification of Friction Welding of Metals

For ordering information, contact Global Engineering Documents, 15 Inverness Way

East, Englewood, Colorado 80112-5776. Telephone:(800)854-7179, (303)397-2740;
Internet:www.global.ihs.com.